• Part 1 - Header & Exhaust Install
• Part 2 - Supercharger Install
• Part 3 - Lowering Kit Install
• Part 4 - Wheel & Tire Install
• Part 5 - Big Brake Install
• Part 6 - Electric Fan Install
Illustration by Jimmy Smi...
Illustration by Jimmy Smith
Thus far, our Project Dark Horse '04 two-wheel-drive Ford F-150 has received a big boost in the horsepower department by adding a Powerdyne blower, JBA headers, and a Bassani exhaust system. Now, it's time to give the truck a little altitude adjustment by installing a high-quality lowering kit from McGaughy's Suspension, in Fresno, California.
For more than 20 years, McGaughy's has been a leader in the lowering suspension market. "We are always challenging ourselves with producing lowering suspension parts that haven't been done before in the world and doing it right the first time," says Mike McGaughy. "We ride on our reputation for our parts being a bolt-on installation and making sure the entire lowering kit works hand-in-hand with necessary factory components."
The '04 Ford 2WD F-150 kit includes complete instructions, which you should read thoroughly before beginning, new lowering coil springs for the front, and a flip kit for the rear, consisting of longer U-bolts, plates, shackles, shock extenders, and bumpstops. It will give our truck a nice 2-inch front drop and a 4 1/2-inch rear drop. We'll be 'baggin' our baby later, so this takes care of the first step in that process as well. You'll need a floor jack, a set of heavy-duty wide-base jackstands, and a good set of handtools with long-handle ratchets for the job. The only special tool needed is a spring/strut compressor, which is available at most tool rentals.
The installation was done at GO-EZ Customs, in Placentia, California, by suspension specialist Scott. GO-EZ is owned and operated by a group of custom automotive enthusiasts and master fabricators with 25 years of experience, who have built the suspensions and twisted the metal of many award-winning show vehicles and at least 30 cover vehicles. Note: Normally, we'd have the truck aligned immediately after lowering it, but we decided to wait until the next day, after we had the new tires and wheels installed, which will be covered next month. The lower stance looks great, and there's plenty of clearance for the 23-inch Tezzen wheels and Nitto tires. So, follow the photos, and you'll see how simple it was to get Dark Horse down with a drop kit from McGaughy's.
 The 2-inch front, 4 1/2-inch...  The 2-inch front, 4 1/2-inch rear drop kit for '04 Ford 2WDs includes drop front coil springs and a rear flip kit with shackles, longer U-bolts, plates, shock extenders, and bumpstops. |  With the truck in Park, the...  With the truck in Park, the emergency brake on, and the rear tires chocked, the front end is raised and secured on jackstands. Then, the tires and wheels are removed, revealing the stock coil-over strut assembly. |  Begin by unbolting the tie...  Begin by unbolting the tie rod end from the front hub assembly. |
 Then, unbolt the top of the...  Then, unbolt the top of the strut from the tower. |  Next, unbolt the bottom of...  Next, unbolt the bottom of the strut and remove it. Since the suspension is at full droop, the strut assembly should slide right out. |  A spring compressor must be...  A spring compressor must be used to remove the spring from the strut. Note: After removing the spring, remove the plastic cap on the top of the strut, cut the foam bumpstop in half, and replace the cap. |